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Version 1

Combustion Chamber Cleaning Procedure

29. Reconnect the Condensate drain to the neutralizer and/or drainpipe

30. Turn the manual gas shut off valve on.

Test for gas leaks. Verify the gas system is leak tight.

31. Operate the boiler

and check for smooth ignition and proper burner operation

32. Perform a combustion test.

Using an electronic combustion analyzer, verify the high fire CO2 reading equals the value in the table

below. Adjust if necessary. Refer to the boiler’s installation manual, section 5, for procedural information.

Boiler Model

Gas Type

PCH 34B H

Nat

9.1

LPG

10.3

PCH 50B H

Nat

9.4

LPG

10.3

PCC 34 H

Nat

9.1

LPG

10.3

PCI 18/8 H &

PCH 18B H

Nat

9.3

LPG

10.1

PCI 34/20 H

Nat

9.1

LPG

10.3

Содержание PCC 34 H

Страница 1: ...Pensotti ASME Condensing Boilers Cleaning Procedure Version 1 All Models 1 ...

Страница 2: ...i ASME Condensing Boilers Table of Contents Service Requirements Pg 3 Safety Precautions Pg 5 Combustion Chamber Cleaning Procedure Pg 7 Diverter Valve Lubrication Pg 29 Water Test and Treatment Pg 30 Version 1 ...

Страница 3: ... in the following problems Plugged combustion passages Reduced heating capacity Increased flue gas temperatures Flue gas thermo fuse failures generating an E03 Error Code Rough ignition Ignition failure generating an E01 Error Code Ignition electrode failure Ionization rod failure Pulsating combustion Heat exchanger failure Contributing factors to the build up of soot and foreign debris on the hea...

Страница 4: ...rating on LP Gas and those installed in environments containing high levels of pollutants or chemical vapors in the combustion air may need to be cleaned more frequently The frequency of a cleaning schedule will need to be determined by the servicing company based on the condition of the heat exchanger at the time of cleaning Dirty Heat Exchanger Blocked Heat Exchanger Passages ...

Страница 5: ...ds the instructions and information provided Warning Handling Instructions for Refractory Ceramic Fibers Exposure Risk Precautions and Recommended Personal Protective Equipment Prevent contact with skin and eyes Wear safety glasses or googles Wear gloves Wear long sleeve shirts and pants Wear a disposable cover all Prevent breathing of silica dust Wear an approved respirator with N95 rated filter ...

Страница 6: ...ld result in personal property damage personal injury explosion or death Important Before performing a cleaning and inspection Turn off all electrical power to the boiler Remove the power cord from the electrical outlet Turn the manual gas shut off valve in the gas line of the boiler to the closed position Prepare a clean safe work area around the boiler Warning Do not operate this boiler if any p...

Страница 7: ...0B Remove the single Philips screw from the top edge of the cover screw faces the ceiling Grasp both the top and bottom of the cover firmly and pull The cover is secured with male female spring clips Model PCI34 20 Remove the single Philips screw from the top edge of the cover screw faces the ceiling Grasp both the top and bottom of the cover firmly and pull The cover is secured with male female s...

Страница 8: ...ignition electrode cable from the ignition transformer B The ground wire from the ignition electrode C The cable on the gas valve D The pressure switch hose from the gas venturi E The 2 cables connected to the fan motor F PCH50B ONLY remove the combustion air tube from the gas venturi by loosening the clamp F E D C B A ...

Страница 9: ...Version 1 9 Combustion Chamber Cleaning Procedure F F E D ...

Страница 10: ...Version 1 10 Combustion Chamber Cleaning Procedure 5 Flip the control panel down by spreading the 2 retaining bracket handles ...

Страница 11: ...Cleaning Procedure 6 Locate the inlet and outlet gas tube connections to the gas valve and disconnect the nuts These are gasketed fittings carefully remove the gaskets if in good repair retain for later use Replace any damaged gasket ...

Страница 12: ...cated at the inlet side of the gas valve below the sheet metal shelf the gas valve is mounted on There are 4 Philips head screws 2 recessed into the sheet metal and 2 securing the gas valve to the sheet metal shelf Only remove the 2 screws securing the gas valve Retain the screws Gaskets Recessed Remove ...

Страница 13: ...Version 1 13 Combustion Chamber Cleaning Procedure 8 Remove the gas valve Place it in a safe location to avoid any potential damage ...

Страница 14: ...g a 10mm wrench or socket loosen the 4 nuts securing the burner to the main heat exchanger Once loose remove 3 of the nuts and place them in a safe location Hold the pre mix burner tube with one hand while removing the final nut Retain the 4 nuts Pre mix Tube ...

Страница 15: ...mbly Rotate the left side of the burner assembly a couple of inches away from the main heat exchanger Now pull the assembly straight from the boiler Once free continue to rotate the burner assembly as you remove it from the boiler Warning Caution Internal components may be hot ...

Страница 16: ...nternal burner components Place the burner on a clean flat surface Inspect all the burner components especially the refractory rope gasket and EPDM seal for excessive wear or defect Replace any worn or defective item Burner Refractory EPDM Gasket Rope Gasket Refractory ...

Страница 17: ...ode inspect for excessive wear broken electrode or ground rod or cracked porcelain insulator Replace any worn or defective item Verify the electrode gap is 4mm and the gap between the electrode and burner surface is 7mm If necessary adjust the electrode rods by applying light pressure with your finger and slowly manipulate the rod to the correct position If it is found necessary to replace the ign...

Страница 18: ...the condition of the electrode inspect for excessive wear or cracked porcelain insulator Replace if found to be worn or defective Verify the gap between the electrode and burner surface is 7 5mm If necessary adjust the ionization rod by applying light pressure with your finger and slowly manipulate the rod to the correct position If it is found necessary to replace the ionization electrode it is v...

Страница 19: ...the target wall with water to minimize the amount of air born particles Refer to the safety precautions section of this manual beginning on page 5 before proceeding To avoid damaging the replacement target wall install it only after you have completed the cleaning of the heat exchanger surface Permitting any Pensotti Condensing Boiler to operate with a dirty combustion chamber and heat exchanger w...

Страница 20: ... on page 5 before proceeding Remove the condensate drain hose from the neutralizer and or drain and place into a bucket to collect the cleaning water Using a vacuum with a high efficiency filter remove all of the loose debris from within the combustion chamber and heat exchanger surfaces Warning Vacuum All Loose Debris From the Heat Exchanger Surfaces ...

Страница 21: ... gallon pail cut to size This will reduce the potential of damage caused by the cleaning brush or water spray 16 Using a non metallic brush loosen the debris stuck to the surface of the heat exchanger tubes pay particular attention to the area between all the tubes Remove the dislodged debris with the vacuum Protect the Refractory Brush to Loosen Suck Debris Especially in Between the Tubes ...

Страница 22: ... will eliminate the possibility of damage to these items from sprayed or dripping water 18 Using a garden hose with a trigger spray nozzle or similar device direct pressurized water in the space between the heat exchanger tubes The water should pass freely through the heat exchanger condensate trap and exit through the condensate drain hose into the pre placed bucket ...

Страница 23: ...rect pressurized water in the space between the heat exchanger tubes Repeat steps 18 and 19 until the heat exchanger is thoroughly cleaned and the water running into the bucket remains clear For especially stubborn debris a 50 50 mix of CLR and water may be used in place of just straight water It is imperative that upon completion the heat exchanger be thoroughly rinsed with clean water to remove ...

Страница 24: ...Philips head screws holding the cover to the frame Pull the front edge of the cover away from the boiler approximately 2 inches then lift the entire side panel up towards the ceiling to release the rear retaining tabs Remove the trap by unscrewing the drain hose and top connection do not lose the rubber gaskets Disconnect the 2 condensate safety circuit wires if equipped Clean the trap thoroughly ...

Страница 25: ...rovided in the sheet metal shelf Manipulate the position until the 2 screws at the gas valve manifold drop into the cut outs provided for them Secure the gas valve to the sheet metal shelf with the additional 2 screws Install the gasket between the gas inlet tube and gas valve manifold Slide the nut in place and tighten Install the second gasket between the gas valve manifold and the gas outlet tu...

Страница 26: ...ation electrode cable A The ignition electrode cable B The ground wire to the ignition electrode C The gas valve cable D The pressure switch hose at the gas venturi E The 2 fan motor cables F PCH50B ONLY the combustion air tube to the gas venturi secure the clamp F E D C B A ...

Страница 27: ...otor The fan will now run continually on high speed Temporarily block the exhaust vent only Using a soap and water solution inspect for leaks throughout the burner assembly and it s connection to the heat exchanger Verify no leaks are present then remove the temporary blockage Wipe away the soap and water solution with a clean rag Reconnect the 4 wire cable to the combustion blower motor Check For...

Страница 28: ... smooth ignition and proper burner operation 32 Perform a combustion test Using an electronic combustion analyzer verify the high fire CO2 reading equals the value in the table below Adjust if necessary Refer to the boiler s installation manual section 5 for procedural information Boiler Model Gas Type CO2 PCH 34B H Nat 9 1 LPG 10 3 PCH 50B H Nat 9 4 LPG 10 3 PCC 34 H Nat 9 1 LPG 10 3 PCI 18 8 H P...

Страница 29: ...nt of lubricant directly onto the drive shaft of the diverter valve Wipe away any excess lubricant Failure to lubricate the diverter will result in premature failure and may void the warranty of this item Reinstall the side panel upon completion Superlube is an example Warning Read and follow all safety precautions on the label of lubricant Space Between Motor and Valve Assembly Drive Shaft Brass ...

Страница 30: ...those instructions test the water and if necessary treat as required Keep a detailed history of the water quality test to assist in creating a schedule for future treatments Warning Read and follow all safety precautions on the label of all water treatment chemicals Important Failure to test and treat the boiler water on a regular basis may result in premature failure and will void the warranty 35...

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